US11161156B2 - Powder monitoring - Google Patents
Powder monitoring Download PDFInfo
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- US11161156B2 US11161156B2 US16/510,180 US201916510180A US11161156B2 US 11161156 B2 US11161156 B2 US 11161156B2 US 201916510180 A US201916510180 A US 201916510180A US 11161156 B2 US11161156 B2 US 11161156B2
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- additively manufactured
- state change
- change fluid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
- B08B3/04—Cleaning involving contact with liquid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
- B08B3/04—Cleaning involving contact with liquid
- B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B9/00—Cleaning hollow articles by methods or apparatus specially adapted thereto
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/68—Cleaning or washing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/35—Cleaning
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/22—Devices influencing the relative position or the attitude of articles during transit by conveyors
- B65G47/24—Devices influencing the relative position or the attitude of articles during transit by conveyors orientating the articles
- B65G47/248—Devices influencing the relative position or the attitude of articles during transit by conveyors orientating the articles by turning over or inverting them
- B65G47/252—Devices influencing the relative position or the attitude of articles during transit by conveyors orientating the articles by turning over or inverting them about an axis substantially perpendicular to the conveying direction
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G57/00—Stacking of articles
- B65G57/02—Stacking of articles by adding to the top of the stack
- B65G57/03—Stacking of articles by adding to the top of the stack from above
- B65G57/035—Stacking of articles by adding to the top of the stack from above with a stepwise downward movement of the stack
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G57/00—Stacking of articles
- B65G57/02—Stacking of articles by adding to the top of the stack
- B65G57/09—Stacking of articles by adding to the top of the stack from alongside
- B65G57/10—Stacking of articles by adding to the top of the stack from alongside by devices, e.g. reciprocating, acting directly on articles for horizontal transport to the top of stack
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G57/00—Stacking of articles
- B65G57/02—Stacking of articles by adding to the top of the stack
- B65G57/16—Stacking of articles of particular shape
- B65G57/20—Stacking of articles of particular shape three-dimensional, e.g. cubiform, cylindrical
- B65G57/22—Stacking of articles of particular shape three-dimensional, e.g. cubiform, cylindrical in layers each of predetermined arrangement
- B65G57/24—Stacking of articles of particular shape three-dimensional, e.g. cubiform, cylindrical in layers each of predetermined arrangement the layers being transferred as a whole, e.g. on pallets
- B65G57/245—Stacking of articles of particular shape three-dimensional, e.g. cubiform, cylindrical in layers each of predetermined arrangement the layers being transferred as a whole, e.g. on pallets with a stepwise downward movement of the stack
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F15—FLUID-PRESSURE ACTUATORS; HYDRAULICS OR PNEUMATICS IN GENERAL
- F15D—FLUID DYNAMICS, i.e. METHODS OR MEANS FOR INFLUENCING THE FLOW OF GASES OR LIQUIDS
- F15D1/00—Influencing flow of fluids
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B2209/00—Details of machines or methods for cleaning hollow articles
- B08B2209/005—Use of ultrasonics or cavitation, e.g. as primary or secondary action
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B3/00—Cleaning by methods involving the use or presence of liquid or steam
- B08B3/04—Cleaning involving contact with liquid
- B08B3/10—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
- B08B3/12—Cleaning involving contact with liquid with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration by sonic or ultrasonic vibrations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/70—Recycling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/02—Control or detection
- B65G2203/0266—Control or detection relating to the load carrier(s)
- B65G2203/0283—Position of the load carrier
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/02—Control or detection
- B65G2203/0266—Control or detection relating to the load carrier(s)
- B65G2203/0291—Speed of the load carrier
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present disclosure relates to additive manufacturing methods and systems, more specifically to methods and systems for powder removal and inspection for additively manufactured articles.
- Certain methods for additive manufacturing using powder beds cause powder to be left within internal passages of the additively manufactured article.
- powder beds e.g., selective laser sintering
- components When components are made in the additive laser powder bed fusion process, residual entrapped powder can remain inside internal cavities and channels.
- Agitation or vibration methods can be used to remove unsintered powder from additive components. It is imperative that all the unsintered powder is removed from the channels before the components go onto the next steps of the process, specifically heat treatment.
- computed tomography CTScan
- a method includes issuing a state change fluid into an internal passage of an additively manufactured article and causing the state change fluid to change from a first state having a first viscosity to a second state that is either solid or has a second viscosity that is higher than the first viscosity within the internal passage.
- the method can also include causing the state change fluid to change back from the second state to the first state and flushing the state change fluid from the internal passage to remove residual powder from the additively manufactured article.
- the method can include applying vibration, such as ultrasonic vibration, to the additively manufactured article while the state change fluid is in the second state.
- Causing the state change fluid to change from the first state to the second state can include applying heat to the state change fluid.
- the state change fluid can include poly(N-isopropylacrylamide) or any other suitable thermal-responsive polymer that becomes more viscous or solidifies with added heat.
- Causing the state change fluid to change from the first state to the second state can include cooling the state change fluid.
- the state change fluid can include an ionic liquid that is crystalline at room temperature and melts to freely flow above room temperature.
- the ionic liquid can include [bmim]NTf 2 .
- the method can further include heating the ionic liquid to change the ionic liquid from the second state to the first state before inputting the ionic liquid into the internal passage.
- Causing the state change fluid to change from the first state to the second state can include applying a pressure or force to the state change fluid.
- the state change fluid can include a non-Newtonian fluid that becomes more viscous or rigid with applied kinetic energy.
- Inputting the state change fluid can include applying a pressure to the state change fluid.
- Causing the state change fluid to change from the first state to the second state can include removing the applied pressure or reducing pressure to the state change fluid.
- the state change fluid can include a non-Newtonian fluid that flows more freely with higher pressure (e.g., a clay suspension).
- an additively manufactured article includes an internal passage, the internal passages being cleared of residual powder by any suitable portion or combination of portions of a method as described above.
- FIG. 2 is a cross-sectional elevation view of an embodiment of an additively manufactured article having an internal flow passage, showing a state change fluid flowing therethrough in a first state;
- FIG. 1 an illustrative view of an embodiment of a method in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100 .
- FIGS. 2-3B Other embodiments and/or aspects of this disclosure are shown in FIGS. 2-3B .
- the systems and methods described herein can be used to remove residual powder from within internal passages of additively manufactured articles, for example.
- a method 100 includes inputting (e.g., at block 101 ) a state change fluid 205 into an internal passage 201 of an additively manufactured article 200 .
- the method 100 also includes causing (e.g., at block 103 ) the state change fluid 205 to change from a first state having a first viscosity (e.g., as shown in FIG. 2 ) to a second state that is either solid (e.g., as shown FIG. 3A ) or has a second viscosity that is higher than the first viscosity (e.g., as shown in FIG. 3B ) while the state change fluid 205 is within the internal passage 201 .
- a first viscosity e.g., as shown in FIG. 2
- a second state that is either solid (e.g., as shown FIG. 3A ) or has a second viscosity that is higher than the first viscosity (e.g., as shown in FIG. 3B ) while the state change fluid
- causing the state change fluid 205 to change from the first state to the second state can include applying heat to the state change fluid 205 .
- the state change 205 fluid can include poly(N-isopropylacrylamide) or any other suitable thermal-responsive polymer that becomes more viscous and/or solidifies with added heat.
- an additively manufactured article 200 includes an internal passage 201 , the internal passage 201 being cleared of residual powder by any suitable portion or combination of portions of a method 100 as described above.
- Piezoelectric impedance monitoring 109 is used to make non-destructive evaluation to validate that all the powder has been removed from the additive part.
- Piezoelectric impedance evaluation 109 is a fast and inexpensive method for evaluations of powder removal within the channels.
- the impedance-based monitoring system uses an impendence evaluator, such as piezoelectric wafers, as collocated sensors and actuators simultaneously excite the structure of interest and measure the response.
- the impedance measuring device is connected to the additive part. Once impedance measurements 109 have been acquired, the results are compared against an already verified “clean” additive part or with no residual powder left in channel.
- the presence of metal powder in the part will alter the damping characteristics and thus alter the measured dynamic response of the part.
- the expected results can be calculated based the material and material thickness or density, or the expected results can be based on a previously validated exemplary part. If the piezoelectric impedance is measured at a value outside the acceptable range, the build plate and components can go back for continued powder removal, rather than scrapping the parts. Previous methods required a percentage of parts to be destructively measured to prove that the lot of parts was able to be used in service. This method however is costly and does not positively prove that each part is completely free of powder.
Abstract
Description
Claims (4)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/510,180 US11161156B2 (en) | 2015-10-27 | 2019-07-12 | Powder monitoring |
EP20185536.8A EP3763446A1 (en) | 2019-07-12 | 2020-07-13 | Powder monitoring |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/924,046 US10220422B2 (en) | 2015-10-27 | 2015-10-27 | Powder removal |
US16/292,173 US20190193124A1 (en) | 2015-10-27 | 2019-03-04 | Powder removal |
US16/510,180 US11161156B2 (en) | 2015-10-27 | 2019-07-12 | Powder monitoring |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/924,046 Continuation-In-Part US10220422B2 (en) | 2015-10-27 | 2015-10-27 | Powder removal |
US16/292,173 Continuation-In-Part US20190193124A1 (en) | 2015-10-27 | 2019-03-04 | Powder removal |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US16/292,173 Division US20190193124A1 (en) | 2015-10-27 | 2019-03-04 | Powder removal |
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Publication Number | Publication Date |
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US20190329300A1 US20190329300A1 (en) | 2019-10-31 |
US11161156B2 true US11161156B2 (en) | 2021-11-02 |
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US16/510,180 Active 2036-04-28 US11161156B2 (en) | 2015-10-27 | 2019-07-12 | Powder monitoring |
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Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20200376766A1 (en) * | 2019-05-29 | 2020-12-03 | United Technologies Corporation | Method and system for removing residual powder from an additively manufactured article |
US11717910B2 (en) * | 2020-11-03 | 2023-08-08 | General Electric Company | Monitoring operation of electron beam additive manufacturing with piezoelectric crystals |
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